Paint, and method of producing the same

ABSTRACT

A paint has a film-forming binder component, a color-producing component, and a fire-retardant component adapted to least substantially protect from fire a surface of which the paint is applied; and the paint is produced by a method including providing a film-forming binder component; providing a color-producing component; mixing the components with some of dried powder components missing; and adding afire retardant component to replace the dry powder component.

This application claims the benefit of Provisional Application No. 60/280,789, filed Apr. 2, 2001.

BACKGROUND OF THE INVENTION

The present invention generally relates to paints, and methods of producing paints.

Paints are widely known and utilized in industry, household, and other areas of modern life. Known paints usually include a film-forming binder component which provides formation of a film and adhesion to a substrate on which the paint is to be applied, and also include a color-producing component, such as for example pigments and other coloring agents.

While the known paints provide a certain protection of surfaces on which they are applied from deleterious action of atmosphere and impart certain colors to the surfaces on which they are applied, they do not adequately protect the surfaces of the substrates of the consequences of a fire. It is believed to be advisable to eliminate this disadvantage.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a paint which avoids the disadvantages of the prior art, and a method of producing a paint.

In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a paint which has a film-forming binder component; a color-producing component; and a fire-retardant component adapted to at least substantially protect from fire a surface of which the paint is applied.

When the paint is designed in accordance with the present invention, then in addition to conventional characteristics of the paint it also protects a surface of a substrate in which it is applied at least substantially from consequences of fire, in many cases it increases a corrosion resistance, and lengthens the service life of the paint.

In accordance with a further feature of the present invention the fire retardant component includes at least one phosphate or its derivative, such as melamine polyphosphate, ammonium polyphosphate.

In accordance with still a further feature of the present invention the fire retardant component includes melamine or is derivative selected from the group consisting of melamine cyanurate, melamine borate, melamine polyphosphate, melamine diphosphate, melamine pyrophosphate and melamine phosphate.

Also, in accordance with a present invention a method for producing a paint is proposed, which has the steps of providing a film-forming binder component; providing a color-producing component, mixing the components with some dried powder components missing; and adding a fire retardant component to replace the dry powder component.

The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In accordance with the present invention a paint is provided which has a film-forming binder component; a color-producing component; and a fire-retardant component adapted to least substantially protect from fire a surface of which the paint is applied.

The fire retardant component can include phosphate or its derivative such as melamine polyphosphate, ammonium polyphosphate.

Also, the fire retardant component can include melamine or its derivative such as melamine cyanurate, melamine borate, melamine polyphosphate, melamine diphosphate, melamine pyrophosphate and melamine phosphate.

In the paint in accordance with the present invention the fire retardant component can include a charring agent, which is for example pentaerythritol, mono-pentaerythritol or di-pentaerythritol a blowing agent which for example is melamine, and an additional agent selected from the group of agents specified herein above.

It is to be understood that in addition to film generating substances (binding materials and softeners) which are one of the main components of paints which affect durability, shine, elasticity, bonding, flexibility and hardness, and also in addition to pigments which can be color powders not soluble in binders and soluble in color agents so as to create color variations and surface coloring capability the paint can also include volatile components which in combination with the binding materials create in most cases solution or so-called base lacquer (varnish). Also additives can be included in the paint, which are “helping” chemicals creating specific characteristics of the paints.

The paint in accordance with the present invention can be produced by a method which includes the steps of providing a film-forming binder component; providing a color-producing component, mixing said components with some of dried powder components missing; and adding a fire retardant component to replace the dry powder component.

In particular, fillers, such as for example calcium carbonate and titanium dioxide, are substituted by the fire retardant component. However, it is of course possible to substitute small amounts of film generating component.

The paint in accordance with the present invention is illustrated by the following examples:

EXAMPLE 1

Epoxy Paint-Two Components

Part A

Function Material Weight % Part A Liquid Epoxy Epotuf 37-127 32.80 Film Forming Binder Resin Diluent Benzyl Alcohol 3.75 Film Forming Binder Dispersant BYK P-104S 0.32 Additives Anti-Crater BYK A-530 0.15 Additives Additive Flow Additive BYK 501 0.16 Additives Prime Pigment Titanox2020 12.3 Color Producing Component Extender Microna 7 18.99 Dry Powder Component Blowing Agent Melamine 5.25 Fire Retardant Component Catalyst Melamine 4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol 5.25 Fire Retardant Component Part B Polyamine Epotuf 37-801 13.32 Film Forming Binder Hardener Diluent Benzyl Alcohol 3.21 Film Forming Binder 100.00

Mix Part A/Part B 4/1 by Volume

EXAMPLE 2

Alkyd Undercoat

Function Material Weight % Medium Oil Beckosol AA-203  31.48 Film Forming Binder Aklyd 80% Solvent Mineral Spirits  21.94 Volatile Component Dispersant Soya Lecithin  0.13 Additives Thixotrops Thixatrol ST  0.32 Thixotrope Sag Control Post 4  0.44 Thixotrope Cobalt Drier 12% Cobalt  0.08 Additives Naphthenate Calcium Drier 6% Calcium  0.78 Additives Naphtenate Anti-Skin Agent Methyl Ethyl  0.33 Additives Ketoxine Prime Pigment Tipure 902  21.40 Color Producing Comp Extender Pigment Nicron 604  8.12 Dry Powder Component Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.25 Fire Retardant Component 100.00

EXAMPLE 3

Urethane Enamel

Function Material Weight % Oil Modified Spenkel  50.10 Film Forming Binder Polyurethane F47-M-60 Dispersant Nuosperes 657  0.46 Additives Thixotrope Bentone SD-1  0.95 Thixotrope Solvent Mineral Spirits  6.18 Volatile Component Prime Pigment Tronox CR-828  23.90 Color Producing Comp Cobalt Drier 12% Cobalt  0.38 Additives Naphthenate Calcium Drier  6% Calcium  1.26 Additives Naphthenate Zirconium Drier 24% Zirconium  1.61 Additives Naphthanete Anti-Skin Agent Exkin #2  0.11 Additives Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerytritol  5.25 Fire Retardant Component 100.00

EXAMPLE 4

Strippable Vinyl Coating

Function Material Weight % Vinyl Resin Ucar YVNS  7.38 Film Forming Binder High M.W. Vinyl Resin Ucar VYHD  3.69 Film Forming Binder Low M.W. Plasticizer Dioctyl Phthalate  2.88 Film Forming Binder White Pigment TiPure 902  6.50 Color Producing     Component Diluent Toluene  22.20 Volatile Component Ketone Solvent Methyl Isobutyl  20.95 Volatile Component Ketone Acetate Solvent Butyl Acetate  21.40 Volatile Component Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.25 Fire Retardant Component 100.00

EXAMPLE 5

Nitrocellulose Satin Lacquer

Function Material Weight % Low MW Nitrocellulose  6.75 Film Forming Binder Nitrocellulose ¼ sec High MW Nitrocellulose  0.10 Film Forming Binder Nitrocellulose ½ sec Diluent Toluene  13.75 Volatile Component Lateral Solvent Isopropanol  2.70 Volatile Component Fast Solvent Butyl Acetate  27.60 Volatile Component Slow Solvent PM Acetate  2.70 Volatile Component Coconut Alkyd Bookosol 91-470  12.78 Film Forming Binder 70% in BA Plasticizer Dioctyl Phthalate  1.34 Film Forming Binder White Pigment TiPure 902  9.80 Color Producing Comp Crosslinker Cymel 303  6.95 Film Forming Binder Crosslinker Butyl Acid  0.53 Additives Catalyst Phosphate Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.25 Fire Retardant Component 100.00

EXAMPLE 6

Eggshell Latex Paint

Function Material Weight % Solvent Water  25.3 Volatile Component Dispersant Potassium  0.22 Additives Tripolyphosphate Surfactant Igepal CO-630  0.84 Additives Defoamer Colloid 643  0.23 Additives Wet Edge Control Propylene Glycol  2.77 Additives Biocide Nuosept 95  0.38 Additives White Pigment Tipure 902  18.14 Color Producing Comp Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.5 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.25 Fire Retardant Component Celluolosic Bernocol  0.32 Thixotrope Thickener E411 FQ Latex Rovace 9100  34.88 Film Forming Binder Polymer 55% pH Adjustment 28% Ammonia  0.13 Additives Hydroxide Associative Acrysol RM-5  1.82 Thixotrope Thickener 100.00

Method of Preparation

The above samples were prepared by a Cowles High Speed Disperser. Following a normal paint manufacture technique, the powdered materials were dispersed at highspeed into a suitable amount of the vehicle which contained the dispersants and wetting agents. After the dispersion was complete the speed was reduced balance of the vehicle was added together with the remaining ingredients in the formula.

EXAMPLE 7

Acrylic Powder Coating

Function Material Weight % Glycidyl Acrylic Fine-Clad  56.90 Film Forming Binder Polymer A-207-SA Crosslinker Dodecanedioic  10.83 Film Forming Binder Acid Flow Additive Silwet L-7500  0.33 Additives White Pigment Titanox 2020  16.94 Color Producing Comp Blowing Agent Melamine  5.26 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.28 Fire Retardant Component 100.00

Bake Temperature: 20 minutes at 150 C.

Method of Preparation

Powders were mixed and blended using a W&P ZSK-30 Blender.

Barrel Temperature 60/80 C.

Screw Speed: 250 rpm.

Classification: 100% through 200 mesh.

As can be seen from the above presented examples, the fire-retardant part of the paint in accordance with the present invention is composed of three fire-retardant components, namely melamine, melamine polyphosphate, and pentaerythritol. These fire-retardant components can together amount to only 15 weight percent of the paint.

It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of substances and methods differing from the types described above.

While the invention has been illustrated and described as embodied in paint, and method of producing the same, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.

Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. 

What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims:
 1. A paint for painting a surface in a predetermined color, comprising a film-forming binder component for forming a film of the paint on the surface; a color-producing component for providing the predetermined color on the surface; and a fire-retardant component adapted to protect the surface from consequences of fire; and additional components including a filler and en additive, wherein said fire retardant component includes in ratio by weight 35% melamine, 35% pentaerythritol, and 30% melamine polyphosphate.
 2. A paint as defined in claim 1, wherein said fire retardant component includes 5.25 weight % of melamine, 5.25 weight % of pentaerythritol, and 4.50 weight % of melamine polyphosphate from total weight % of the paint.
 3. A paint as defined in claim 1, wherein said fire retardant component does not exceed 15 weight % of the paint.
 4. A paint as defined in claim 1, wherein the paint includes the following components: EXAMPLE 1 Function Material Weight % Part A Liquid Epoxy Epotuf 37-127 32.80 Film Forming Binder Resin Diluent Benzyl Alcohol 3.75 Film Forming Binder Dispersant BYK P-104S 0.32 Additives Anti-Crater BYK A-530 0.15 Additives Additive Flow Additive BYK 501 0.16 Additives Prime Pigment Titanox2020 12.3 Color Producing Component Extender Microna 7 18.99 Dry Powder Component Blowing Agent Melamine 5.25 Fire Retardant Component Catalyst Melamine 4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol 5.25 Fire Retardant Component Part B Polyamine Epotuf 37-801 13.32 Film Forming Binder Hardener Diluent Benzyl Alcohol 3.21 Film Forming Binder 100.00

Mix Part A/Part B 4/1 by volume
 5. A paint as defined in claim 1, wherein the paint includes the following components: EXAMPLE 2 Function Material Weight % Medium Oil Beckosol AA-203  31.48 Film Forming Binder Aklyd 80% Solvent Mineral Spirits  21.94 Volatile Component Dispersant Soya Lecithin  0.13 Additives Thixotrops Thixatrol ST  0.32 Thixotrope Sag Control Post 4  0.44 Thixotrope Cobalt Drier 12% Cobalt  0.08 Additives Naphthenate Calcium Drier 6% Calcium  0.78 Additives Naphtenate Anti-Skin Agent Methyl Ethyl  0.33 Additives Ketoxine Prime Pigment Tipure 902  21.38 Color Producing Comp Extender Pigment Nicron 604  8.12 Dry Powder Component Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.25 Fire Retardant Component 100.00


6. A paint as defined in claim 1, wherein the paint includes the following components: EXAMPLE 3 Function Material Weight % Oil Modified Spenkel  50.10 Film Forming Binder Polyurethane F47-M-60 Dispersant Nuosperes 657  0.46 Additives Thixotrope Bentone SD-1  0.95 Thixotrope Solvent Mineral Spirits  6.18 Volatile Component Prime Pigment Tronox CR-828  23.95 Color Producing Comp Cobalt Drier 12% Cobalt  0.38 Additives Naphthenate Calcium Drier  6% Calcium  1.26 Additives Naphthenate Zirconium Drier 24% Zirconium  1.61 Additives Naphthanete Anti-Skin Agent Exkin #2  0.11 Additives Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerytritol  5.25 Fire Retardant Component 100.00


7. A paint as defined in claim 1, wherein the paint includes the following components: EXAMPLE 4 Function Material Weight % Vinyl Resin Ucar YVNS  7.38 Film Forming Binder High M.W. Vinyl Resin Ucar VYHD  3.69 Film Forming Binder Low M.W. Plasticizer Dioctyl Phthalate  2.88 Film Forming Binder White Pigment TiPure 902  6.50 Color Producing     Component Diluent Toluene  22.20 Volatile Component Ketone Solvent Methyl Isobutyl  20.95 Volatile Component Ketone Acetate Solvent Butyl Acetate  21.40 Volatile Component Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.25 Fire Retardant Component 100.00


8. A paint as defined in claim 1, wherein the paint includes the following components: EXAMPLE 5 Function Material Weight % Low MW Nitrocellulose  6.75 Film Forming Binder Nitrocellulose ¼ sec High MW Nitrocellulose  0.10 Film Forming Binder Nitrocellulose ½ sec Diluent Toluene  13.75 Volatile Component Lateral Solvent Isopropanol  2.70 Volatile Component Fast Solvent Butyl Acetate  27.60 Volatile Component Slow Solvent PM Acetate  2.70 Volatile Component Coconut Alkyd Bookosol 91-470  12.78 Film Forming Binder 70% in BA Plasticizer Dioctyl Phthalate  1.34 Film Forming Binder White Pigment TiPure 902  9.80 Color Producing Comp Crosslinker Cymel 303  6.95 Film Forming Binder Crosslinker Butyl Acid  0.53 Additives Catalyst Phosphate Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.25 Fire Retardant Component 100.00


9. A paint as defined in claim 1, wherein the paint includes the following components: EXAMPLE 6 Function Material Weight % Solvent Water  25.3 Volatile Component Dispersant Potassium  0.22 Additives Tripolyphosphate Surfactant Igepal CO-630  0.84 Additives Defoamer Colloid 643  0.23 Additives Wet Edge Control Propylene Glycol  2.77 Additives Biocide Nuosept 95  0.38 Additives White Pigment Tipure 902  18.14 Color Producing Comp Blowing Agent Melamine  5.25 Fire Retardant Component Catalyst Melamine  4.5 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.25 Fire Retardant Component Celluolosic Bernocol  0.32 Thixotrope Thickener E411 FQ Latex Rovace 9100  34.88 Film Forming Binder Polymer 55% pH Adjustment 28% Ammonia  0.13 Additives Hydroxide Associative Acrysol RM-5  1.82 Thixotrope Thickener 100.00

Method of Preparation The above samples were prepared by a Cowles High Speed Disperser. Following a normal paint manufacture technique, the powdered materials were dispersed at highspeed into a suitable amount of the vehicle which contained the dispersants and wetting agents. After the dispersion was complete the speed was reduced balance of the vehicle was added together with the remaining ingredients in the formula.
 10. A paint as defined in claim 1, wherein the paint includes the following components: EXAMPLE 7 Function Material Weight % Glycidyl Acrylic Fine-Clad  56.90 Film Forming Binder Polymer A-207-SA Crosslinker Dodecanedioic  10.83 Film Forming Binder Acid Flow Additive Silwet L-7500  0.33 Additives White Pigment Titanox 2020  16.94 Color Producing Comp Blowing Agent Melamine  5.26 Fire Retardant Component Catalyst Melamine  4.50 Fire Retardant Component Polyphosphate Carbonific Pentaerythritol  5.28 Fire Retardant Component 100.00

Bake Temperature: 20 minutes at 150 C. Method of Preparation Powders were mixed and blended using a W&P ZSK-30 Blender. Barrel Temperature 60/80 C. Screw Speed: 250 RPM. Classifiction: 100% through 200 mesh. 